This workbook is intended to assist in selecting the appropriate size for each line of a hydraulic system.

Hydraulic lines should be sized large enough to carry the flow with an acceptable pressure loss but
should be no larger than necessary. Undersize piping creates high pressure losses and can result in
excess power consumption, noise, erosion, and heat. Oversize piping will reduce losses but will be more
expensive to purchase and built.

Input data into the following fields; Application (optional), Flow Rate, Fluid, Temperature, Tube/Pipe
Size. The calculations in this workbook generate two outputs, average velocity and pressure drop. They
should be used together to determine the appropriate line size.

Good system design requires an analysis of pressure losses created by fittings, valves, other
components, and layout, which is not considered here.

Velocity Consideration

Generally, the average velocity calculation is an effective way to choose an acceptable line size for given
conditions. Using the guidelines below will result in pressure losses in the piping that are not significant
compared to the operating pressure and will reduces the need to calculate equivalent line lengths and
pressure loss. This method works well for piping within the boundaries of a skid utilizing typical
hydraulic fluids.

Applications that use high gravity or high viscosity fluids such as glycol, cool hydraulic oil, or lube oils
require additional analysis.

This method should not be used where the flow is cyclic or pulsating as will be the case were piston or
diaphragm pumps are used. With these pumps, the peak flow as each pumping chamber discharges will
be much higher than the average flow and will result in significant acceleration head. Follow the pump
manufacturers recommendations for sizing the fluid lines, particularly the suction line.

- Pump suction lines should be sized so the fluid velocity is between 3 and 5 feet per second.

- Low pressure lines and fluid return lines operating at less than 500 psi should be sized so the fluid
velocity is between 7 and 10 feet per second.

- Medium pressure lines operating from 500-2000 psi can be sized so the fluid velocity is between 10
and 20 feet per second.

- High pressure lines operating above 2000 psi should be sized so the fluid velocity is below 30 feet per
second.

Pressure Drop Considerations

This method calculates only the frictional losses in straight lengths of commercial tubing or pipe using
the Darcy formula. Pressure losses due to changes in elevation, acceleration, or direction are not
considered. Since the frictional pressure loss is a function the fluid velocity this calculation is a more
detailed look at the effects of the fluid properties for a given line size.

Generally, high viscosities and densities may result in unacceptable pressure losses even when the
velocity fall within the acceptable range defined above. On long or complex lines, the pressure drop can
be significant.
- Pump suction lines should be sized so the pressure loss is less than 1 psi/100 feet.

- Pressure lines should be sized so the pressure loss is less than 5 psi/100 feet

References

Pressure Drop Calculations – Crane Technical Paper 410

Viscosity Calculations – ASTM D341

Specific Gravity - None

Acceptance Criteria – Womack Machine Supply Catalog 365